Method for fabricating containers

ABSTRACT

A method for fabricating containers wherein a molding apparatus is provided having a plurality of mold segments, each of which has two substantially opposite faces that form a mold cavity when abutted against an opposite face of an adjacent mold segment. A first mold segment is passed through a manipulation zone at an increased speed to open the mold cavity between the first and second mold segments. After a preform is positioned within the mold cavity, a second mold segment is passed through the manipulation zone at an increased speed to abut a face of the first mold segment against an opposite face of the second mold segment. A volume of a liquid is next injected into the preform, expanding the preform and forming the container. These steps are repeated and a container produced during the previous iteration is removed during an extracting step in an extracting manipulation zone.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No. 14/652,861filed Jun. 17, 2015, which is the national phase of PCT Application No.PCT/EP2013/075632 filed Dec. 5, 2013, which claims priority to EuropeanPatent Application No. 12198191.4 filed Dec. 19, 2012, the disclosuresof which are incorporated in their entirety by reference herein.

FIELD OF THE INVENTION

This invention relates generally to an apparatus for fabricatingcontainers. This invention also relates to a method for fabricatingcontainers, as well as the containers so produced.

BACKGROUND OF THE INVENTION

It is well known to fabricate containers by process of blow molding,wherein a blank parison or “preform” is positioned within the cavity ofa mold and injected with a pressurized gas, usually air, causing it toinflate and assume the contours of the mold cavity. The contours of themold are configured in the shape of a container, such that when thepreform is inflated within the mold it is thereby formed into acontainer.

One common variant of this is the stretch blow molding process, whereinthe preform is mechanically stretched along a longitudinal axis whilebeing inflated. Preforms used in a stretch blow molding process have aclosed end, such that the preform generally resembles a test tube with aclosed end and a mouth at an open end. These preforms are also generallyprovided with flanges, threads, etc. at the mouth, to permit theattachment of a closure device to the mouth of the finished container.

During the stretch blow molding process, a stretching rod or similardevice is inserted into the mouth of the preform and advanced, pushingat the preform from within and stretching it along its longitudinal axisas the air is injected. The mouth of the preform remains substantiallyun-deformed, while the body of the preform is stretched and expanded tomatch the contours of the mold in which it has been placed.

Stretch blow molding is thus particularly well-suited for thefabrication of elongated containers, namely those used for packagingmineral water and other beverages. While this document is concerned withthe use of the stretch blow molding process for the fabrication ofbeverage containers, it should be understood that the principlesdiscussed herein may be equally applicable to the fabrication ofcontainers for other substances and applications.

Apparatuses for stretch blow molding comprise, at the least, theaforementioned mold (optimally provided in two or more mobile segmentsto facilitate extraction of the finished container) and an injectionhead for injecting pressurized gas into the cavity of the preform, andpossibly inserting and removing the stretch rod.

The apparatus may have a single chamber, but more frequently is providedin a multiple-chamber form with multiple molds. Using multiple moldswill improve the output of the container fabrication process, which isgreatly advantageous in commercial container fabrication and bottlingoperations.

In high-volume stretch blow molding implementations, these molds areconventionally disposed upon the circumference of a large, rotatingwheel. The mold is opened when the wheel reaches a certain angularposition, the preform is inserted and the mold closed around it, and theinjection head injects the gas into the preform as the wheel rotates,such that by the time the wheel returns to the initial angular positionthe container within the mold segment is completely formed and removedfor cleaning, filling, and sealing.

By utilizing a wheel with multiple molds and having multiple injectionheads acting on multiple preforms disposed within the molds, containersmay be produced continuously and at a very high rate of productionrelative to a single-mold apparatus. When operated in combination with afilling and sealing line, tens of thousands of filled and sealedcontainers may be so produced. Generally speaking, the higher the numberof mold cavities disposed on the wheel, the higher the rate at which thecontainers may be fabricated.

One particular embodiment of this principle is found in the documentEP1226017, which describes a molding apparatus wherein there is aplurality of mold segments each configured so as to form a mold cavitywith the corresponding face of an adjacent mold segment. These moldsegments are not disposed upon the edge of a wheel, but at the ends ofradial supports resembling spokes, so as to revolve about a common axis.

The radial supports may be further adapted with means to permit theradial displacement of the mold segments, both in an absolute sense andrelative to each other, and may be further adapted so as to permit anaxial displacement of a mold segment. By way of these displacementmeans, each of the mold cavities between the mold segments are openedand closed during the operation of the molding apparatus.

However, the apparatuses known in the prior art require a considerableamount of floor space when implemented in a container fabricating andfilling operation. Along with the wheel-shaped forming apparatus, oneneed supply at least an apparatus for filling the containers with theliquid product, as well as transport belts or carriers for moving thepreforms and containers between them. This limits the production thatany one facility may realize for a given floor space and may make anincrease in production prohibitively expensive.

Furthermore, the apparatuses known in the prior art require a great dealof energy to operate. Specifically, it is desirable to clamp the moldsegments together during the molding operation to prevent the formationof a mark in the surface of the container along the parting line wherethe mold segments meet. One must therefore furnish means of clamping themold segments together with great force. This requires a great deal ofenergy and entails the addition of still more machinery, furtherincreasing the space required for the molding apparatus and thecomplexity of its construction and operation.

It is therefore an object of this invention to provide a moldingapparatus which is more space-efficient than the ones known in the art,and which consumes less energy during the production of containers.

SUMMARY OF THE INVENTION

According, therefore, to a first aspect, the invention is drawn to anapparatus for fabricating containers, comprising a plurality of moldsegments, each of the mold segments being provided with at least twosubstantially opposite faces configured to form a mold cavity whenabutted against an opposite face of another mold segment, the moldcavity substantially defining the form of a container; and a guidingmeans configured to serially conduct the plurality of mold segments in acyclical succession along a closed path, the length of the closed pathbeing greater than a total length of the mold segments when abuttingagainst each other.

According to the invention, the apparatus is characterized in that itcomprises at least one injecting head, the at least one injecting headconfigured to inject a volume of liquid into a cavity of asubstantially-tubular preform positioned between two of the moldsegments and at least partially disposed within the mold cavity formedby the mold segments, thereby causing the preform to expand into thecontours of the mold cavity and form a container; and furthercharacterized in that each mold segment is conducted along the closedpath through at least one manipulation zone of the closed path at anincreased speed relative to the speed of the immediately adjacent moldsegments, the apparatus comprising a positioning manipulation zonewherein the preform is inserted into the apparatus, and an extractingmanipulation zone wherein the container is extracted from the apparatus.

This is advantageous in that when the liquid injected into the preformis that which is packaged within the container, the container isfabricated and filled with a product in a single step and by a singleapparatus. An apparatus according to the invention will thereforeobviate the need for any additional means for filling the containers ortransporting them from the forming apparatus to the filling apparatus.

This aspect is further advantageous in that a container-fabricatingapparatus so configured will consume less energy to fabricate acontainer than the ones known in the art, in that the pressure increasewithin the mold cavities during the operation of the apparatus areemployed to ensure that each container is properly molded.

During the operation of the apparatus, the pressure within the moldcavities is elevated as the liquid is injected into the preform and thepreform is expanded. When the preform is expanded into contact with thewall of the mold cavity itself, it is necessary to hold the moldsegments together, such that the expanding preform does not push themold segments apart but instead assumes the smallest details of the formof the mold cavity.

At the instant a particular preform is expanded into contact with thesurface of the mold cavity, the preform in the cavity immediatelyfollowing it will be pressurized from the injection of the liquid intothe preform positioned therein. The container within the immediatelypreceding cavity will have been nearly completely formed, itselfexerting a pressure on the walls of the preceding mold cavity. The twomold segments which form the mold cavity into which the particularpreform is expanding into contact are thereby held together by thepressure within the immediately adjacent cavities.

In this way, the amount of energy required to maintain the mold segmentstogether at the moment when the preform is expanded into the contours ofthe mold cavity is reduced, improving the economy and efficiency of theoperation of the apparatus. The quality of the containers produced isalso improved, in that the formation of a mold separation line in thecontainer is prevented by the compressive force on the mold segments.

According to a feature, the apparatus is provided with at least twomanipulation zones, the preform being inserted into the mold cavity at apositioning manipulation zone and the container removed from twoimmediately adjacent mold segments at an extracting manipulation zone.

This is advantageous in that performing the insertion of the preform andthe removal of the container at two different manipulation zones willresult in a portion of the closed path in which there is no preform orcontainer disposed within the mold cavities. This portion of the closedpath may be employed to carry out any of a number of ancillary stepsenhancing the operation of the apparatus. In this way, the capabilityand flexibility of the apparatus and its operation are enhanced.

In a preferable embodiment, a means for cleaning the mold cavities isprovided between the extracting and positioning manipulation zones. Thisis advantageous in that the mold cavities are thereby regularly cleanedwithout having to stop the molding apparatus or otherwise interrupt theproduction of containers. Furthermore, providing a means for cleaning inthe apparatus ensures that the mold cavities are free of dirt, grease,or other such contaminants, improving the cleanliness and quality of thecontainers produced and maintaining the purity of the products heldtherein.

According to another feature, the apparatus further comprises at leastone closure device for applying a closure to a mouth of a container, theat least one closure device being disposed so as to move in concert witha mold segment.

This is advantageous in that the entire range of processes required toproduce a container ready for sale are combined in a single apparatus.The space required for a container fabricating and filling operation isthereby reduced as compared to the prior art, permitting one to increaseproduction without requiring a corresponding increase in factory floorspace. Furthermore, carrying out the entire forming and filling processon a single machine reduces the complexity of the operation as a whole.The capacity and economy of the production of filled containers isthereby improved.

Preferably, the at least one closure device is positioned relative tothe container by the relative motion of the mold segments forming themold cavity in which the container is formed.

This is advantageous in that the closure device is positioned relativeto the mold cavity without need for an additional actuator or othermotion device, the positioning of the closure device being effectuatedby the motion of the mold segments along the closed path, e.g. though amanipulation zone. The apparatus is thereby rendered simpler, morereliable, and less expensive to operate.

According to another feature, there is one closure device provided forevery mold segment.

This is advantageous in that the speed at which the apparatus may beoperated is maximized. As there is one closure device for every moldsegment, the portion of the cycle dedicated to positioning the closuredevice over the container is minimized. In this way, the total time ofeach cycle of operation of the apparatus is minimized. The output of theapparatus is thereby improved.

Alternately, there is one closure device provided for every two moldsegments.

This is advantageous in that the overall complexity of the apparatus isreduced. By providing one closure device for every other mold segment,the total number of closure devices is reduced, resulting in acorresponding reduction of components in the apparatus. The operation ofthe apparatus is thereby rendered more reliable.

According to another feature, each closure device is mounted upon a moldsegment.

This is advantageous in that the overall complexity and size of theapparatus is reduced. Since the closure device is mounted upon, andthereby mobile with, a mold segment, it is unnecessary to provideadditional actuators to move the closure device. Furthermore, thecombination of the closure device with a mold segment will result in asmaller container production line overall. The apparatus according tothe invention thus offers improved performance in a more compact packagerelative to the apparatuses known in the art.

According to still another feature, each mold segment comprises aretaining means for retaining a closure in proximity to a mold cavityprior to its application to the container within the mold cavity.

This is advantageous in that the closure is pre-positioned prior to itsapplication to the container. The range of motion required for theoperation of the closure device is thereby minimized, improving thespeed at which the closures are applied to the containers and maximizingthe output of the apparatus.

According to still another feature, the closed path is provided in theform of a polygon with rounded corners.

This is advantageous in that the closed path is configured so as tocomprise a number of straight sections, corresponding to the faces ofthe polygon. Each of the faces may be provided with manipulation zones,injection heads, closure devices, etc. such that as each mold segmentpasses along the segment of the closed path corresponding to a face ofthe polygon, a container is produced. The provision of rounded cornersserves to maintain a smooth transit of the mold segments about theclosed path, maintaining speed and efficiency of operation of theapparatus and reducing wear. In this way, one effectively combinesseveral apparatuses into one, thereby increasing the output of theapparatus and rendering its operation more cost-effective.

According to a second aspect, the invention is drawn to a method for thecontinuous fabrication of containers, comprising the steps of (a)providing a molding apparatus comprising a plurality of mold segments,each of the mold segments being provided with at least two substantiallyopposite faces configured to form a mold cavity when abutted against anopposite face of another mold segment, the plurality of mold segmentsbeing disposed upon a guiding means conducting the mold segments in acyclical succession along a closed path, the length of the closed pathbeing greater than a total length of the mold segments when abuttingagainst each other; (b) passing a first mold segment through apositioning manipulation zone disposed along the closed path at anincreased speed relative to an adjacent second mold segment, therebyopening the mold cavity disposed within the first and second moldsegments; (c) positioning a substantially tubular preform between thefirst and second mold segments, the preform defining a preform cavityand having a mouth disposed at an open end communicating with thecavity; (d) passing the second mold segment through the positioningmanipulation zone and accelerating it relative to the adjacent firstmold segment, thereby abutting a first face of the first mold segmentagainst an opposite second face of the second mold segment, the preformbeing thereby at least partially enclosed within a mold cavity formed bythe first and second faces; and (e) injecting a volume of a liquid intothe cavity of the preform, thereby inducing the preform to expand intothe contours of the mold cavity and form a container; wherein steps (b)through (e) are repeated in the molding apparatus, the containerproduced in the previous iteration being removed in an extracting stepas the surrounding mold segments pass through an extracting manipulationzone.

This method is advantageous in that it realizes the advantages of theapparatus embodying it as described above, efficiently producing filledcontainers at a high rate.

In particular, the method is configured to take advantage of thecyclical nature of the motion of the mold segments along the closedpath, such that a preform inserted into the mold cavity of two moldsegments will be conducted about a portion of the closed path as it isbeing formed into a container, eventually returning to the initial pointof the closed path where the method may be repeated. By providing manymold segments which form many mold cavities, the method is executed suchthat at any given moment, there is at least one preform/containerundergoing every step of the method. In this way, the method isperformed in a way that maximizes the output of formed and filledcontainers.

Furthermore, the method is advantageous in that the provision of aplurality of mold segments upon a closed path is inherently versatile,permitting a great number of adaptations and modifications to the basicmethod to meet the requirements of any particular application.

In one possible configuration, the inserting and extracting manipulationzones are coterminous.

This is advantageous in that it minimizes the complexity of theapparatus employed to carry out the method of the invention. Theperformance of the method of the invention is thereby rendered moreefficient and reliable, improving the economy of the fabrication ofcontainers embodying this configuration.

In another possible configuration, there is provided a separationbetween the extracting and positioning manipulation zones along theclosed path.

This is advantageous in that the method is rendered more flexible andversatile. In particular, the separation of the extracting andpositioning manipulation zones results in a portion of the closed pathbetween the two where the mold cavities are empty. This portion may beprovided as a queuing section, enabling the apparatus to adjust tovariations in the speed of its operation without disrupting the feed ofthe mold segments through the closed path.

Alternately, the portion of the closed path between the extracting andpositioning manipulation zones may be employed for the performance ofancillary steps not strictly necessary for the fabrication of acontainer but which must be periodically performed to maintain theintegrity of the operation, such as inspection, lubrication, or cleaningsteps.

Preferably, the method comprises at least an additional step forcleaning the mold cavity after the removing step. This is advantageousin that a high level of cleanliness is maintained in the containersproduced by the method, without requiring one to periodically halt theprocess and disassemble the apparatus to clean its components. In thisway, the output of the method of the invention is maintained at ahighest possible level of quality, without sacrificing efficiency ofoperation.

According to another feature, the method further comprises a closingstep after the injection step, wherein a closure is applied to thecontainer by a closure device, the closure device being positioned bythe relative motion of the first and second mold segments through amanipulation zone.

This is advantageous in that the incorporation of a closing step willresult in a container that is fabricated, filled, and sealed in a singleprocess which is economically performed by a single apparatus. Theentire process of producing a container which is ready for sale is thusperformed in as few steps, and with as few machines, as possible,reducing the overhead costs of such an operation and permitting agreater number of production lines to be located in the same factoryspace. The process is thereby made more economical.

According to another feature, the method is performed over two laps ofthe closed path, the positioning and injecting steps being performedduring the first lap and the closing and extracting steps beingperformed during the second lap.

This is advantageous in that performing the method over two laps of theclosed path will double the effective length of the closed path, whilemaintaining its actual length unchanged. In this way, the method may beadapted to produce containers which require different forming rates orcharacteristics, without modifying the line itself or altering the speedat which the mold segments are conducted about it. In this way, themethod is rendered more versatile and adaptable.

According to still another feature, the steps of the method are repeatedat least twice over each circuit of the closed path.

This is advantageous in that the method produces more than one containerper mold cavity for each lap of the closed path the mold segments make.In this way, the output of the method and the apparatus embodying it areimproved.

According to a third aspect, the invention is drawn to a beveragecontainer as produced by the method described above.

This is advantageous in that such a beverage container will embody theadvantages of the method as previously enumerated.

Other particularities and advantages of the invention will also emergefrom the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, given by way of non-limiting examples:

FIG. 1 is a perspective view of an embodiment of a mold segmentaccording to a first embodiment of the invention;

FIG. 2 is a top orthogonal view of an apparatus according to theinvention in the first embodiment, during a positioning step;

FIG. 3 is a top orthogonal view of the apparatus of FIG. 2, during anextracting step;

FIG. 4 is a side section view of an apparatus during an injecting step;

FIG. 5 is a top orthogonal view of an apparatus according to theinvention in a second embodiment;

FIG. 6 is a top orthogonal view of an apparatus according to theinvention in a third embodiment;

FIG. 7 is a perspective view of a closure device and a closure uponwhich it is configured to operate;

FIG. 8A is a perspective view of a mold segment comprising a retainingmeans for retaining a closure, according to a feature of the invention;

FIG. 8B is a side view of the retaining means for retaining a closureseen in FIG. 8A;

FIG. 8C is a top view of the retaining means for retaining a closureseen in FIG. 8A;

FIG. 9 is a perspective view of a trio of mold segments disposed inrelation to the closure device of FIG. 7 and incorporating two retainingmeans of FIG. 7; and

FIG. 10 is a perspective view of a mold segment comprising an injectionhead and the closure device of FIG. 7.

DETAILED DESCRIPTION

As the method and apparatus of this invention deal with containersfabricated by blow molding, the basic principles and components of blowmolding processes and apparatuses, including those in which employ aliquid as the working fluid, are taken as understood by the reader. Thefollowing description should therefore be read in this context.

FIG. 1 depicts a first mold segment 100 according to a first embodimentof the invention. The first mold segment 100 is a block substantially inthe form of a segment of an extruded annulus, being thereby providedwith a substantially parallel interior face 101 and exterior face 102and a substantially parallel top face 103 and bottom face 104. The firstmold segment 100 is further provided with two substantially oppositemold faces 105, the mold faces 105 being disposed so as to converge atan angle T defining the segment.

The mold faces 105 are provided with a first mold depression 106, whichis in this embodiment configured to substantially define one half of theform of a beverage container. The first mold depression extends to thetop edge 107 of the mold face 105, thereby forming the neck hole 108 inthe top face 103 of the first mold segment 100. When the mold face 105of the first mold segment 100 is abutted against a corresponding moldface of another mold segment, the two first mold depressions 106 willthereby form a mold cavity which substantially defines the form of acontainer.

The neck hole 108 is preferably configured so as to just accommodate theinsertion of a substantially-tubular first preform 109, depicted herefor reference. The top face 103 of the first mold segment 100 is furtherprovided with a counterbore 110, such that a flange 111 of the firstpreform 109 will seat therein when the first preform 109 is disposedwithin the mold cavity formed by the first mold depressions 106. An openend 112 of the first preform 109 will therefore sit outside the moldcavity when two first mold segments 100 are closed about it, the rest ofthe first preform 109 being disposed within the mold cavity.

Of course, the exact form of the first mold depressions 106 and the moldcavity they form, as well as the necessary size and proportions of thefirst preform 109 needed to form a container in that mold cavity, may bereadily determined by one skilled in the art.

The first mold segment 100 is further provided with a means forinterfacing with a guiding means, as depicted here in the rail grooves113. The rail grooves 113 are configured to accommodate the rails 114,depicted here in dashed lines. The rails 114 are configured to form aclosed path, such that the first mold segment 100 may be cyclicallyconducted about the closed path. In this embodiment the rail grooves 113are plain, though it may instead be advantageous to provide rollers,wheels, lubrication, or other such means for facilitating the motion ofthe first mold segment 100 upon the rails 114 and about the closed path.

FIG. 2 depicts a first apparatus 200 for fabricating containers,according to the first embodiment, during a positioning step. The firstapparatus 200 here comprises eleven first mold segments 100, herenumbered as 100A through 100K. The first mold segments 100A-100K aredisposed upon a pair of rails 114 which are here configured in a circle;the first mold segments 100A-100K may thus circulate about the firstclosed path 201 (here represented in a dashed line, offset from thecenterline of the first mold segments 100A-100K for clarity).

This embodiment is exemplary and it should be understood, of course,that more or fewer mold segments may be provided, according to therequirements of the particular application in which the apparatus is tobe employed.

During the operation of the apparatus, the first mold segments 100A-100Kare conducted around the first closed path 201 on the rails 114 at aglobally constant speed 202. The first mold segments 100A-100K may beconducted about the first closed path 201 by propulsion means such aschains, belts, rollers, gears, or any other means appropriate to theparticular application in which the first apparatus 200 is to beemployed.

In this embodiment, the first mold segments 100A-100K circulate aboutthe first closed path 201 in a substantially contiguous bloc, beingabutted end-to-end. The first mold segments 100A-100K thereby form thefirst mold cavities 203A-203K (203A is not shown in this figure).

During the positioning step, the first mold segment 100A is advancedinto the manipulation zone 204. The manipulation zone 204 corresponds tothe segment of the circular closed path defined by the angle a. In thisembodiment, the size of the manipulation zone 204 is substantially equalto the space occupied by two first mold segments 100, though the size ofthe manipulation zone 204 may in fact be increased or decreasedaccording to the particular operational characteristics of theapparatus, such as the size of the containers it is employed to produce.

Upon entering the manipulation zone 204, the first mold segment 100A ispassed along the first closed path 201 with an acceleration 205. Thiswill cause it to approach the first mold segment 100B, ultimatelyabutting against it. The first preform 109 is then inserted into themold cavity 200A (not shown) formed by the first mold depressions 106Aand 106B.

It should be understood that for illustrative purposes the first preform109 is depicted in FIG. 2 in the position where it will be inserted intothe mold; however, during the operation of the first apparatus 200 themold segments 100A and 100B are abutted against each other before thefirst preform 109 is inserted into the mold cavity 200A (not shown).Preferably, the means for inserting the first preform 109 are configuredto avoid scraping, scratching, or other unnecessary contact between thefirst preform 109 and the mold segments 100A and 100B.

FIG. 3 depicts the first apparatus 200 of FIG. 2, in an extracting step.The first mold segment 100A has advanced to the end of the manipulationzone 204, coming into abutment with the first mold segment 100B andenclosing the first preform 109 in the first mold cavity 203A. At thesame time, the first mold cavity 203K depicted in FIG. 2 is opened bythe passing of the first mold segment 100A through the manipulation zone204, exposing the first mold depressions 106A and 106K and permittingthe finished first container 300 to be extracted from within.

Preferably, the positioning and passing steps depicted in FIG. 2 and theextracting step depicted in FIG. 3 are performed substantiallysimultaneously. In other words, the first preform 109 is positioned inbetween the first mold segments 100A and 100B and the first container300 is extracted from between the first mold segments 100A and 100K atthe same time, while the first mold segment 100A is being passed thoughthe acceleration zone 204 with acceleration 205 between the twopositions depicted in FIGS. 2 and 3. The manipulation zone 204 thus actsboth as a positioning manipulation zone and an extracting manipulationzone.

During the operation of the first apparatus 200, the first preform 109is positioned between the first mold segments 100A and 100B. The firstpreform 109 is enclosed within the first mold cavity 203A, preferablywith an open end protruding from the first mold segments 100A and 100Bas described above, when the first mold segment 100A is passed throughthe manipulation zone 204. As the first mold segments 100A and 100B areconducted around the first closed path 201, an injection means injects aliquid into a cavity of the preform, inducing it to expand into a firstcontainer 300 which is extracted when the first mold segments 100A and100B come back around to the manipulation zone 204.

The first apparatus 200 is most advantageously configured such that afirst preform 109 is inserted and a first container 300 removed eachtime a first mold segment 100 is passed through the manipulation zone204. By providing a plurality of injection means, one may employ thefirst apparatus 200 to fabricate and fill large quantities ofcontainers.

Furthermore, the first apparatus 200 realizes a considerable energysavings relative to the machines known in the art, in that it is notnecessary to provide means for clamping the first mold segments 100together during the forming process, as demonstrated in FIG. 4.

FIG. 4 depicts a cross-section of the first mold segments 100I to 100Aof the first apparatus 200 at the moment depicted in FIG. 2. In FIG. 4,there are three containers 300 at different stages of their fabrication.The first container 300I is nearly complete, having been expanded by theinjection of liquid 400I into all but the smallest details of the of thefirst mold cavity 203I. The first container 300J is depicted at themoment where its fabrication is complete; the injection of liquid 400Jhas caused the first container 300J to assume all of the details of thefirst mold cavity 203J. The first container 300K is completed, but stillremains pressurized and disposed within the first mold cavity 203K asthe first mold segment 100A has not yet been passed through themanipulation zone.

In order to prevent a separation line from being molded into the firstcontainer 300J where the first mold segments 100J and 100K separate atseam 401 J, it is necessary to maintain the first mold segments 100J and100K together. While the first mold segments 100J and 100K are initiallypositioned in abutment, the expansion of the first container 300J intothe small details of the first mold cavity 203J will exert a lateralforce 402J on the first mold segments 100J and 100K. The first moldsegments 100J and 100K are prevented from separating by the lateralforces 402I and 402K exerted on the first mold segments 100J and 100K,respectively. The lateral forces 402I and 402K, generated by thepressurization within the containers 300I and 300K respectively, willcounteract the lateral forces 402J, maintaining the first mold segments100J and 100K in abutment and preventing the formation of a separationline in the first container 300J.

It should be understood that the person skilled in the art will have agreat deal of flexibility in choosing where along the closed path theinjection of the liquid and the fabrication of the container iscompleted. While in this embodiment the first mold cavities 203I-203Kare disposed as close as possible to the manipulation zone 204, one mayoptionally configure the apparatus such that there are additional firstmold segments 100 between the manipulation zone 204 and the first moldcavity 203 in which the fabrication of the first container 300 is beingcompleted. For instance, it may be preferable to provide a space betweenthe conclusion of injection and the extraction of the finished firstcontainer 300, e.g. to permit the liquid in the container to settle orfor any foam therein to dissolve.

FIG. 5 depicts a second apparatus 500, according to a second exemplaryembodiment. The second apparatus 500 is similar to the first apparatus200 depicted in FIGS. 2-4: it comprises a plurality of second moldsegments 501A to 501I, disposed upon the rails 502 and being movedaround the second closed path 503 (depicted here, as above, offset fromthe centerline of the second mold segments 501A to 501I for clarity) ata globally constant speed 504.

The operation of the second apparatus 500 is substantially the same asin the first apparatus 200 of the first embodiment. The second apparatus500 differs, however, in that it comprises two manipulation zones: apositioning manipulation zone 505 defined by the angle beta, and anextracting manipulation zone 506 defined by the angle gamma. At thepositioning manipulation zone 505, a second preform 507 is positionedbetween the second mold segments 501D and 501E. The second mold segment501D is passed through the positioning manipulation zone 505 with anacceleration 508, such that it will abut the second mold segment 501 Eand enclose the second preform 507 within a second mold cavity 509D (notpictured) formed from the second mold depressions 510D and 510E.

At the opposite side of the second apparatus 500, the second moldsegment 501A has been passed through the extracting manipulation zone506, separating the second mold segment 501 A from the second moldsegment 501I and exposing the second container 511 such that it may beremoved from the second apparatus 500.

The second apparatus 500 is configured such that the second moldsegments 501 not disposed between the positioning manipulation zone 505and the extracting manipulation zone 506, i.e. those in which there isnot a second preform 507 in the process of being fabricated into asecond container 511, are not abutted against each other but instead areseparated by gaps along the second closed path 503. The exact length ofthese gaps may be determined by those skilled in the art for eachparticular application, by varying such factors as the overall size ofthe apparatus, the size of the second mold segments 501 themselves, thespeed 504, and the acceleration with which the second mold segments 501are passed through the positioning and extracting manipulation zones 505and 506.

The gaps between the mold segments 501 permit a great deal offlexibility in the design of the apparatus. In this second embodiment, aseries of mechanisms are disposed in the gaps for cleaning and dryingthe mold depressions 510 disposed in the mold segments 501.

Specifically, a washing means 512 is positioned in the gap between thesecond mold segments 501A and 501B, and is configured to wash the molddepressions 510A and 510B facing the gap. Similarly, a rinsing means 513is positioned in the gap between the second mold segments 501B and 501C,and a drying means 514 is positioned in the gap between the second moldsegments 501C and 501D. The mold cavities 509 are thereby kept as cleanas possible, maintaining a high level of quality in the output of thesecond apparatus 500 in an industrial setting.

FIG. 6 depicts a third embodiment, similar again to the first and secondembodiments described in the preceding Figures. The third apparatus 600is further provided with four manipulation zones: two positioningmanipulation zones 601 and two extracting manipulation zones 602.Twenty-five third mold segments 603 are disposed upon rails 604, whichconduct the third mold segments 603 about a third closed path 605 with arotation 606, the third closed path 605 being substantially configuredin the shape of a rectangle with rounded corners.

The two positioning manipulation zones 601 and two extractingmanipulation zones 602 are positioned in pairs on the long sides of thethird closed path 605, such that a third mold segment 603 beingconducted about the third closed path 605 will be passed through apositioning manipulation zone 601 at the beginning of a long side 607 ofthe third closed path 605, be conducted along the long side 607 of thethird closed path 605, and be passed through an extracting manipulationzone 602 at the end of the long side 607. Along each of the long sides607 are ideally disposed means for injecting a liquid into a thirdpreform 608 to expand it into a third container 609. The third apparatus600 is thereby configured to fabricate twice as many containers for eachlap of a mold segment around a closed path as the first and secondapparatuses 200 and 500.

In a possible variant mode of realization, one may provide fourmanipulation zones, one on each corner of the third apparatus 600, eachfunctioning as both a positioning and an extraction manipulation zone asin the apparatus depicted in FIGS. 2 and 3. Such a configuration wouldresult in one container being produced by a given mold cavity for eachside of the third apparatus 600.

Furthermore, each of the corners would by its nature serve as amanipulation zone, in that the third mold segments 603 will undergo anangular acceleration and separate from each other as shown in FIG. 6.These separations may thus be employed to insert and remove preforms andcontainers, thereby permitting the apparatus to be further reduced insize.

It should be understood that while the three embodiments discussed up tothis point employ closed paths 201, 503, and 605 configured insubstantially regular forms, one advantage of the invention is that theclosed path of an apparatus may be provided in infinitely many differentforms. The closed path may therefore be optimized for each particularinstallation, for instance to meet certain required production levels orto adapt to an irregular factory space.

Thus, while the three apparatuses 200, 500, and 600 are disposed insubstantially circular and rectangular forms, it is of course possibleto employ other regular polygons (e.g. a triangle), non-convex polygons(e.g. a star), or even irregular shapes, with single or multiplepositioning and extracting manipulation zones.

Furthermore, the closed path may be adapted to enclose other machinerynecessary to the container fabrication process but not incorporated intothe apparatus per se. In FIG. 6, it is shown that the area inside theapparatus 600 is partially occupied by the ancillary machinery 610.Depending on the particular installation, this ancillary machinery mayinclude any or all of preform thermal conditioners; liquid reservoirs,filters, pumps, and/or other systems for furnishing and injecting theliquid; control systems, automation equipment, and/or operator stations;or other equipment necessary to the process. In this way, the overallfactory floor space required for the installation and use of theapparatus is minimized.

FIGS. 7-10 will disclose several additional features which furtherincrease the effectiveness of a container-fabrication apparatus asdescribed with reference to FIGS. 1 through 6.

FIG. 7 depicts a closure device 700 for applying a closure 701 to amouth of a container. Here, the closure 701 is a standard twist-off cap;however, those skilled in the art will recognize that other closuremeans such as plugs, crown corks, or the like may be employed withappropriate adaptation.

The closure device 700 comprises generally a closure head 702, which isattached by an arm 703 to a mast 704. It is necessary that the closuredevice 700 be capable of engaging and disengaging from the closure 701during operation of an apparatus with which it is integrated, andpreferable that it be capable of further degrees of motion. The mast 704comprises at least one telescoping joint 705, and is preferably providedwith means to permit it to rotate and translate about its vertical axis706. The arm 703 is also provided with a sliding joint, permitting thehead 702 to be displaced in the radial direction 708.

In this way, the closure head 702 can be displaced relative to acontainer, permitting the most efficient application of the closure 701.

The motion of the closure device 700 may be effectuated by meanswell-known to those skilled in the art, for instance gearing, racks orleadscrews; pulley and cable or cog and chain arrangements; pneumatic orhydraulic actuators; linear electric motors, or any combination thereof.It is preferable to configure this equipment such that as much of it isfixed as possible, such as by disposing it within the base of the mast704. This will reduce the inertia of the closure device 700 and permitit to be positioned as quickly and efficiently as possible duringoperation.

The head 702 is provided with a closure socket 709, configured to actupon the closure 701. In this embodiment, the closure socket 709 isprovided with an inner cup 710, which is shaped to grasp the closure 701when pressed upon it. Preferably, the inner cup 710 retains the closure701 just tightly enough to prevent it from falling out duringpositioning and to permit it to be screwed onto a container, but not sotightly as to damage the closure 701 if overly-tightened or to impedethe head 702 of the closure device 700 from being disengaged from theclosure 701 once applied.

While this document employs friction to retain the closure 701 in theclosure socket 709 during operation, it should be understood that otherretaining means such as mechanical pincers or vacuum suction mayalternately be employed.

The closure socket 709 is rotatably driven by an actuator 711 housedwithin the head 702 of the closure device 700. In this embodiment, theactuator 711 is a pneumatic motor, driven by pressurized air 712 fed inthrough the air supply hose 713. In other embodiments, it may instead bepreferable to employ other kinds of actuators, for instance a steppermotor.

Preferably, the apparatus is configured with manipulation zonespositioned such that the mold segments are separated, and the moldcavity thereby held open, during the closure of the finished container.This is especially preferable in that it maximizes the clearance betweenthe closure means and the rest of the apparatus during the operation ofthe former.

FIG. 8A depicts a mold segment provided with a pair of retaining means800 for retaining a closure 701, according to a feature of theinvention, while FIGS. 8B and 8C respectively depict side and top detailviews of the retaining means 800.

As can be seen in FIG. 8A, a fourth mold segment 801 is provided with apair of retaining means 800, disposed upon the fourth mold segment 801in proximity to the two mold depressions 802 disposed therein. Theretaining means 800 will thus retain a closure 701 in close proximity tothe mold cavity formed by the mold depressions 802, minimizing thedistance that the closure device will have to travel during theapplication of the closure 701 to a container fabricated by theapparatus.

FIGS. 8B and 8C respectively depict a side view and a top view of theretaining means 800. The retaining means 800 is substantially in theform of a ring 803 which surrounds a closure 701 disposed within it. Theretaining means 800 is configured to hold the closure 701 in place withenough force to keep it from being jarred loose as the fourth moldsegment 801 is moved, but not so much as to impede the removal of theclosure 701 by a closure device when the closure 701 is to be applied toa container.

In this embodiment, this is accomplished by providing a plurality ofleaf springs 804, disposed about the interior of the ring 803. The leafsprings 804 are disposed so as to gently compress the closure 701,thereby retaining it in position yet permitting the closure 701 to beextracted without a great deal of force.

Preferably, the closure 701 is inserted in the retaining means 800during a positioning step as described above. The exact means forinserting the closure 701 into the retaining means 800 may be adaptedfrom techniques known in the art of materials handling and automation,and will not be discussed here.

While this embodiment employs a simple leaf spring mechanism, otherembodiments may employ other means for retaining the closure 701 inplace, such as clamps, tabs, suction devices, and the like. Aparticularly advantageous alternative is configured in the form of apeg, upon which the closure 701 is disposed, the peg havingsubstantially the same dimensions as the mouth of a container andretaining the closure 701 by friction. Moreover, even when employing aspring-type retaining system as depicted here in FIGS. 8A to 8C, thereremains room for variation in the number, size, shape, positioning, andstiffness of the leaf springs 804. The configuration of the retainingmeans 800 as depicted in FIGS. 8A to 8C should therefore be consideredas exemplary rather than limiting.

FIG. 9 depicts the retaining means 800 of FIGS. 8A to 8C as incorporatedinto an apparatus 900 according to the invention. Two retaining means800 are disposed on every other fourth mold segment 801, alternatingwith fourth mold segments 801 which are not provided with retainingmeans 800. As in the previous embodiments, the fourth mold segments 801Ato 801C are borne along the closed path 901 of which this Figure depictsa portion.

A closure device 700 is also provided. The closure device 700 is mountedindependently of the fourth mold segments 801, upon such means as aturret or the like, such that it moves along a closure device path 902substantially parallel with and concentric to the closed path 901 alongwhich the fourth mold segments 801A to 801C are conducted. The closuredevice 700 moves along the closure device path 902 with a variable speed903, such that the closure head 702 of the closure device 700 movesalong with a respective fourth mold segment 801 A in a coarse sense, butits position relative to the fourth mold segment 801 is controllablyvaried in a fine sense. In other words, the closure device 700 followsthe fourth mold segment 801A, but is capable of moving to differentpositions relative to the fourth mold segment 801A.

Of the different positions that the closure head 702 of the closuredevice 700 may be placed in, there are four of particular interest, 904Athrough 904D. During a closing step, the speed of the closure device 700is momentarily altered such that it is disposed in position 904A. Thetelescoping mast 704 and the extending arm 703 position the closure head702 upon the closure 701 held within the retaining device 800 atposition 904A, grasping it securely. The closure head 702 is thendisplaced to position 904B, such that the closure 701 is retracted fromthe retaining means 800 at position 904A and screwed to a containerwithin a mold cavity at position 904B (here omitted for clarity). Theclosure head 702 is then displaced to position 904C to pick up anotherclosure 701 and subsequently to position 904D to screw it to a containerdisposed within a mold cavity at position 904D (again omitted forclarity).

It should be noted that, while this document has thus far described arange of components and actions that comprise the apparatus and itsoperation, one may vary considerably the application of these elementsto achieve different effects.

Most notably, it may be advantageous to configure the apparatus 900 suchthat a preform will make two laps of the closed path 901 before beingextracted. During a first lap a preform is positioned into a mold cavityand injected with a liquid, forming a container. The container thenpasses around the second lap, wherein it is closed with a closure andextracted from the mold. By alternating between preforms on their firstlap and containers on their second from one mold cavity to the next, onemay double the effective length of the closed path and realize theadvantages described above.

FIG. 10 depicts still another possible embodiment for an apparatus 1000for fabricating containers. In particular, FIG. 10 depicts an exemplaryfifth mold segment 1001. The fifth mold segment 1001 is substantiallysimilar to the mold segments 100, 501, 603, and 801 heretoforepresented, with the notable difference in that it includes theinjection-closure assembly 1002, which is mounted thereupon. Theinjection-closure assembly comprises the telescoping mast 1003, to whichtwo rigid arms 1004 are attached, though one of the rigid arms 1004 isdetached for clarity. The telescoping mast is configured to extend andretract and rotate about its y axis as shown.

At the end of one rigid arm 1004 is the injection head 1005. Theinjection head is provided with a nozzle 1006, and is configured toinject a quantity of liquid at pressure through the nozzle 1006 into apreform (omitted for clarity) disposed within a mold cavity 1007 formedby a mold depression 1008 in the fifth mold segment 1001 and acoordinating mold depression in an abutting fifth mold segment (alsoomitted for clarity). At the end of the other rigid arm 1004 is aclosure head 702, as described above. Upon the top of the fifth moldsegment 1001 is a retaining means 800 holding a closure 701, aspreviously described.

During the operation of the apparatus 1000, the telescoping mast 1003will first pivot to align the nozzle 1006 of the injecting head 1005with the mold cavity 1007, and then descend to seat the nozzle 1006 uponthe preform therein. A quantity of liquid is then injected into thepreform, causing it to expand into a container substantially in the formof the mold cavity 1007. The telescoping mast 1003 will then lift theinjecting head 1005 up and pivot to align the closure head 702 with theclosure 701 in the retaining means 800, and then descend to “pick” theclosure 701 from the retaining means and lift it out. The telescopingmast 1003 will then pivot to align the closure head 702 with the moldcavity 1007, and then descend to screw the closure to the container asdiscussed above.

Of course, the invention is not limited to the embodiments describedabove and in the accompanying drawings. Modifications remain possible,particularly as to the construction of the various elements or bysubstitution of technical equivalents, without thereby departing fromthe scope of protection of the invention.

In particular, it should be understood that the invention as describedin the foregoing disclosure is of a highly modular nature, and as suchis not to be considered as being limited to the forms or combinationstherein. Specifically, it should be understood that the exact quantityand form of the components of the apparatus, including the moldsegments, mold depressions and cavities, rails or other guiding means,closed path, etc. may differ considerably from the form of the exemplaryembodiments discussed herein while still remaining within the scope ofthe invention.

The exact configuration and operation of the invention as practiced maythus vary from the foregoing description without departing from theinventive principle described therein. Accordingly, the scope of thisdisclosure is intended to be exemplary rather than limiting, and thescope of this invention is defined by any claims that stem at least inpart from it.

We claim:
 1. A method for fabricating containers, comprising the stepsof: (a) providing a molding apparatus having a plurality of moldsegments, each of the mold segments being provided with at least twosubstantially opposite faces configured to form a mold cavity whenabutted against an opposite face of another mold segment, the pluralityof mold segments being disposed upon a guiding means conducting the moldsegments in a cyclical succession along a closed path, the length of theclosed path being greater than a total length of the mold segments whenabutting against each other; (b) passing a first mold segment through apositioning manipulation zone disposed along the closed path at anincreased speed relative to an adjacent second mold segment, therebyopening the mold cavity disposed within the first and second moldsegments; (c) positioning a substantially tubular preform between thefirst and second mold segments, the preform defining a preform cavityand having a mouth disposed at an open end communicating with thecavity; (d) passing the second mold segment through the positioningmanipulation zone and accelerating it relative to the adjacent firstmold segment, thereby abutting a first face of the first mold segmentagainst an opposite second face of the second mold segment, the preformbeing thereby at least partially enclosed within a mold cavity formed bythe first and second faces; and (e) injecting a volume of a liquid intothe cavity of the preform, thereby inducing the preform to expand intothe contours of the mold cavity and form a container; (f) after theinjecting step, applying a closure to the container by a closure device;(g) wherein steps (b) through (f) are repeated in the molding apparatus,the container produced in the previous iteration being removed in anextracting step as the surrounding mold segments pass through anextracting manipulation zone; and wherein the method is performed overtwo laps of the closed path, the positioning and injecting steps beingperformed during the first lap and the closing and extracting stepsbeing performed during the second lap.
 2. The method of claim 1, whereinthe positioning and extracting manipulation zones are coterminous. 3.The method of claim 1, wherein there is provided a separation betweenthe extracting and positioning manipulation zones along the closed path.4. The method of claim 3, further comprising a step for cleaning themold cavity after the extracting step.
 5. The method of claim 1, whereinduring the closing step the closure device is positioned by relativemotion of the first and second mold segments forming the mold cavity inwhich the container is formed.
 6. The method of claim 1, wherein steps(b) through (e) are repeated at least twice over each circuit of theclosed path.
 7. A method for fabricating containers, comprising thesteps of: (a) providing a molding apparatus having a plurality of moldsegments, each of the mold segments being provided with at least twosubstantially opposite faces configured to form a mold cavity whenabutted against an opposite face of another mold segment, the pluralityof mold segments being disposed upon a guiding means conducting the moldsegments in a cyclical succession along a closed path, the length of theclosed path being greater than a total length of the mold segments whenabutting against each other; (b) passing a first mold segment through apositioning manipulation zone disposed along the closed path at anincreased speed relative to an adjacent second mold segment, therebyopening the mold cavity disposed within the first and second moldsegments; (c) positioning a substantially tubular preform between thefirst and second mold segments, the preform defining a preform cavityand having a mouth disposed at an open end communicating with thecavity; (d) passing the second mold segment through the positioningmanipulation zone and accelerating it relative to the adjacent firstmold segment, thereby abutting a first face of the first mold segmentagainst an opposite second face of the second mold segment, the preformbeing thereby at least partially enclosed within a mold cavity formed bythe first and second faces; and (e) injecting a volume of a liquid intothe cavity of the preform, thereby inducing the preform to expand intothe contours of the mold cavity and form a container; (f) wherein steps(b) through (e) are repeated in the molding apparatus, the containerproduced in the previous iteration being removed in an extracting stepas the surrounding mold segments pass through an extracting manipulationzone; and wherein the closure device moves along with a mold segmentover at least a portion of the closed path.